冷藏集装箱远程监控及故障诊断系统研究
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摘要
我国既是冷藏食品的生产大国又是消费大国,食品物流涉及千家万户。随着我国消费者生活水平的不断提高,人们对于食品品质的要求也越来越高。尤其是需要冷藏保鲜的新鲜食品,如果其冷藏保鲜条件不能达到要求,保鲜效果不好就必然会影响食品的可售卖品质,对商家而言也就意味着市场份额的丧失。
我国的冷藏食品市场是巨大的,随着产销量的快速增长,我国冷藏物流业将进入快速增长时期。
适合食品冷藏运输的设备主要有铁路冷藏车、公路冷藏车、冷藏船及冷藏集装箱。近几十年来,冷藏集装箱运输因其所具有的鲜明的特点和突出的优越性而在全世界范围内迅猛发展。
冷藏集装箱(Reefer Container)是专门为运送有温度要求而特殊设计的集装箱,它是运输需保持一定温度的冷冻货或者鲜货用的集装箱。它具有制冷或保温功能,可用于运输冷冻货或者低温货,如鱼、肉、新鲜水果、蔬菜等食品。
机械式冷藏集装箱是独自带有制冷机组的特殊集装箱,它自带制冷系统,只要插上电源就可以开始制冷降低箱内温度。由于机械式冷藏集装箱多装载于船舶的甲板舱面,受到海上航行特殊情况的制约而工作在十分恶劣的条件中,如环境条件差,时常受到海水侵蚀和日晒雨淋,设备部件常在潮湿的空气中露天工作,运输途中又免不了遇到剧烈碰撞,气候和温度变化和长时间断电等。这些都将增加机组故障率和货物的损坏,影响冷藏集装箱内部装载的货物的保鲜效果和冷藏效果。
因此,开发冷藏集装箱的远程监控与故障诊断系统,对克服以上不利因素,实时监控冷箱运行状态,及时发现冷箱故障并进行排除,对于减少货物损失和保证运输质量具有十分重要的意义。
本文讨论了世界上最先进的冷藏集装箱监控系统——REFCON的监控与工作原理,并结合冷箱模拟海上航行状态下的制冷系统工作数据,分析了正常状态下的工作参数,为冷藏集装箱的故障诊断与排除奠定了基础。同时个人总结了现今冷藏集装箱故障排除研究方面的不足,并针对这些不足提出了自己的改进意见与方向。在此基础上,查阅大量文献资料,总结了比较完全的冷藏集装箱排故资料。采用ACCESS数据库工具和VB等工具,开发了新的船舶冷藏集装箱故障诊断及查询界面。将原有的不足60个故障扩充至近400个;优化了查询界面,使其更加美观、实用、方便。将制冷系统各部件的故障分门别类为13类,分别为活塞式压缩机故障、螺杆式压缩机故障、离心式压缩机故障、封闭式压缩机故障、开启式压缩机故障、热力膨胀阀故障、壳管式水冷冷凝器故障、风机盘管故障、电磁阀故障、油分离器故障、干燥过滤器故障、制冷系统故障、控制系统故障。使用查询更加快捷。该查询系统具有非常实际的意义,可直接应用于冷藏集装箱排故工作。
China is a large country in which refrigerated foods are hugely manufactured and consumed .As the living standard of Chinese people is being improved , requirements for better food quality also rise. Especially for food such as vegetables and meat which need to be refrigerated .If stored in wrong conditions ,the quality of the food will certainly deteriorate .For consumers ,they will not buy the food and for the manufacturers ,they have to face the lose of their market share.
Our market of refrigerated food are a huge one. And with the increasingcapacity of manufacturing and consumption ,our refrigerated food industry willenter a greatly developing period.
Devices for refrigerated food transportation include tracks, trains, ships and reefer containers.These years, reefer containers are greatly developed for their unique advantages and impressing characteristics.
Reefer Containers are specially designed containers for transporting freshcargo They freeze or keep the temperature of the food. So they can be used totransport meat, vegetables or other fresh things.
The mechanical reefer containers are kind of containers with AHU inside .Whatthey need is power to make the AHU work and freeze the food. Considering theworking conditions ,there are evitable damage and loss to both AHU and thecargo. So it's very constructive and meaningful to develop a system for reefercontainers monitoring and failure remove.
This paper discusses the most developed reefer containers monitoringsystem--REFCON, exploring its principles and working conditions. Meanwhile,experiments are made to ensure the right working status of the refrigerating system as a basis of the following work. Using software of ACCESS and VISUAL BASIC, a better system is made for failure remove of reefer containers on a ship .Huge number of failures are contained, more useful solutions are advised, with better interface, the new system and corresponding data-base are much improved than the former one. It includes failures of reciprocating compressor ,screw-type refrigerating compressor ,centrifugal refrigerating compressor ,enclosed compressor ,open-type refrigerating compressor, thermostatic expansion valve, shell and coil condenser, fan-coil, electromagnetic valve, oil-separator, drier-filter, refrigerating system, controlling system .It's a practical system and can be used directly in industry.
我国的冷藏食品市场是巨大的,随着产销量的快速增长,我国冷藏物流业将进入快速增长时期。
适合食品冷藏运输的设备主要有铁路冷藏车、公路冷藏车、冷藏船及冷藏集装箱。近几十年来,冷藏集装箱运输因其所具有的鲜明的特点和突出的优越性而在全世界范围内迅猛发展。
冷藏集装箱(Reefer Container)是专门为运送有温度要求而特殊设计的集装箱,它是运输需保持一定温度的冷冻货或者鲜货用的集装箱。它具有制冷或保温功能,可用于运输冷冻货或者低温货,如鱼、肉、新鲜水果、蔬菜等食品。
机械式冷藏集装箱是独自带有制冷机组的特殊集装箱,它自带制冷系统,只要插上电源就可以开始制冷降低箱内温度。由于机械式冷藏集装箱多装载于船舶的甲板舱面,受到海上航行特殊情况的制约而工作在十分恶劣的条件中,如环境条件差,时常受到海水侵蚀和日晒雨淋,设备部件常在潮湿的空气中露天工作,运输途中又免不了遇到剧烈碰撞,气候和温度变化和长时间断电等。这些都将增加机组故障率和货物的损坏,影响冷藏集装箱内部装载的货物的保鲜效果和冷藏效果。
因此,开发冷藏集装箱的远程监控与故障诊断系统,对克服以上不利因素,实时监控冷箱运行状态,及时发现冷箱故障并进行排除,对于减少货物损失和保证运输质量具有十分重要的意义。
本文讨论了世界上最先进的冷藏集装箱监控系统——REFCON的监控与工作原理,并结合冷箱模拟海上航行状态下的制冷系统工作数据,分析了正常状态下的工作参数,为冷藏集装箱的故障诊断与排除奠定了基础。同时个人总结了现今冷藏集装箱故障排除研究方面的不足,并针对这些不足提出了自己的改进意见与方向。在此基础上,查阅大量文献资料,总结了比较完全的冷藏集装箱排故资料。采用ACCESS数据库工具和VB等工具,开发了新的船舶冷藏集装箱故障诊断及查询界面。将原有的不足60个故障扩充至近400个;优化了查询界面,使其更加美观、实用、方便。将制冷系统各部件的故障分门别类为13类,分别为活塞式压缩机故障、螺杆式压缩机故障、离心式压缩机故障、封闭式压缩机故障、开启式压缩机故障、热力膨胀阀故障、壳管式水冷冷凝器故障、风机盘管故障、电磁阀故障、油分离器故障、干燥过滤器故障、制冷系统故障、控制系统故障。使用查询更加快捷。该查询系统具有非常实际的意义,可直接应用于冷藏集装箱排故工作。
China is a large country in which refrigerated foods are hugely manufactured and consumed .As the living standard of Chinese people is being improved , requirements for better food quality also rise. Especially for food such as vegetables and meat which need to be refrigerated .If stored in wrong conditions ,the quality of the food will certainly deteriorate .For consumers ,they will not buy the food and for the manufacturers ,they have to face the lose of their market share.
Our market of refrigerated food are a huge one. And with the increasingcapacity of manufacturing and consumption ,our refrigerated food industry willenter a greatly developing period.
Devices for refrigerated food transportation include tracks, trains, ships and reefer containers.These years, reefer containers are greatly developed for their unique advantages and impressing characteristics.
Reefer Containers are specially designed containers for transporting freshcargo They freeze or keep the temperature of the food. So they can be used totransport meat, vegetables or other fresh things.
The mechanical reefer containers are kind of containers with AHU inside .Whatthey need is power to make the AHU work and freeze the food. Considering theworking conditions ,there are evitable damage and loss to both AHU and thecargo. So it's very constructive and meaningful to develop a system for reefercontainers monitoring and failure remove.
This paper discusses the most developed reefer containers monitoringsystem--REFCON, exploring its principles and working conditions. Meanwhile,experiments are made to ensure the right working status of the refrigerating system as a basis of the following work. Using software of ACCESS and VISUAL BASIC, a better system is made for failure remove of reefer containers on a ship .Huge number of failures are contained, more useful solutions are advised, with better interface, the new system and corresponding data-base are much improved than the former one. It includes failures of reciprocating compressor ,screw-type refrigerating compressor ,centrifugal refrigerating compressor ,enclosed compressor ,open-type refrigerating compressor, thermostatic expansion valve, shell and coil condenser, fan-coil, electromagnetic valve, oil-separator, drier-filter, refrigerating system, controlling system .It's a practical system and can be used directly in industry.
引文
[1]吴鹰.刘承民.宁奇船舶冷藏集装箱极其监控系统.机电设备,2004(2):23-28
[2]张灼瑞.冷藏集装箱监测系统的发展与现状.广东造船,6(2):21-24
[3]黄晶,刘清,史金山等.冷藏集装箱远程监控系统的数据采集模块系统.PORTOPERATION,2005(6):10-13
[4]孔详洪.承载集装箱的远程监控研究.集装箱化,2006(6):15-19
[5]刘敏,倪海锦.集装箱码头和现代物流中冷藏集装箱远程监控系统的应用.集装箱化,2003(9):33-35
[6]潘盛华.冷藏集装箱载波监控系统的应用.港口装卸,2004(1):18-19
[7]郑为民.冷藏集装箱工况监视与故障分析技术.China Academic Journal Electronic Publishing House,99(7):25-28
[8]许智灵.冷藏集装箱故障诊断与处理的探讨.航海技术,2006(1):60-62
[9]江彦桥,王世良.冷藏集装箱故障统计分析及管理对策.航海技术,94(3):8-9
[10]石博强,申炎华.机械故障诊断的分形方法——理论与时间.北京:冶金工业出版社.2000
[11]种秉林,黄仁.机械故障诊断学.北京:机械工业出版社.1999
[12]虞和济,侯广琳.故障诊断的专家系统.北京:冶金工业出版社.2000
[13]余华明.冷库及冷藏技术.北京:人民邮电出版社.1999
[14]辛长平.制冷设备运行管理与维修.北京:电子工业出版社.2002
[15]张新德.制冷电器维修培训强化教程.北京:人民邮电出版社.2001
[16]冯玉棋,刘旭.制冷装置维修速查图表.北京:人民邮电出版社.2002
[17]郑兆态.制冷装置电气控制系统原理与检修.北京:人民邮电出版社.2002
[18]康宁.常用空调冷冻设备技术.广州:华南理工大学出版社.2002
[19]Althouse,A.D.Modern Refrigeration＆Air-conditioning(彦启森译).上海:上海交通大学出版社.2002
[20]扬茅甄.中国港口协会.国际集装箱港口管理实务.上海:上海人民出版社.2005
[21]江静.国际集装箱运输与多式联运.北京:中国商务出版社.2005
[22]韦在军、夏汉青、郭伟.基于GPRS通信技术的船载远程视频监控系统.数据通信,2004(1):23-26
[23]廖海风.船舶冷藏集装箱故障研究与故障数据库开发:[学位论文].上海海事大学,2004
[24]肖新文.船舶冷藏集装箱制冷系统故障遥测及诊断研究:[学位论文].上海海事大学,2002
[25]张珍.冷藏集装箱远程故障诊断系统研究:[学位论文].上海海事大学,2005
[26]梅雪莲.冷藏集装箱环境室测控系统研究:[学位论文].上海海事大学,2004
[27]彭强.复杂系统远程智能故障诊断技术研究:[学位论文].南京理工大学,2004
[28]王凤岭.ACCESS2002实用教程.北京:电子工业出版社.2003
[29]ACCESS2003数据库管理.北京:人民邮电出版社.2006
[30]江志文.新编Visual Basic程序设计教程第1版.广州:中山大学出版社.2005
[31]李晓黎,张巍.Visual Basic+SQL Server数据库应用系统开发与实例.第1版。北京:人民邮电出版社.2003
[32]曾声奎,赵廷弟,张建国等.系统可靠性设计分析教程.北京:北京航空航天大学出版社.2001
[33]刘鼎铭.冷冻集装箱.北京:人民交通出版社.1985
[34]卢士勋.制冷与空气调节技术.上海:上海科学普及出版社.1992
[35]陈芝久.制冷系统热动力学.北京:机械工业出版社.1998
[36]YORK MARINE.Instruction Manual Operating Guide-REFCON Reefer Container Monitoring System.2006
[37]扬晓楼,许茂增.我国冷藏食品物流市场现状及发展措施.重庆交通学院院报,2005(6):24-26
[38]谢如鹤,韩伯领.国内外冷藏食品物流的现状.中国储运,2004(6):16-18
[2]张灼瑞.冷藏集装箱监测系统的发展与现状.广东造船,6(2):21-24
[3]黄晶,刘清,史金山等.冷藏集装箱远程监控系统的数据采集模块系统.PORTOPERATION,2005(6):10-13
[4]孔详洪.承载集装箱的远程监控研究.集装箱化,2006(6):15-19
[5]刘敏,倪海锦.集装箱码头和现代物流中冷藏集装箱远程监控系统的应用.集装箱化,2003(9):33-35
[6]潘盛华.冷藏集装箱载波监控系统的应用.港口装卸,2004(1):18-19
[7]郑为民.冷藏集装箱工况监视与故障分析技术.China Academic Journal Electronic Publishing House,99(7):25-28
[8]许智灵.冷藏集装箱故障诊断与处理的探讨.航海技术,2006(1):60-62
[9]江彦桥,王世良.冷藏集装箱故障统计分析及管理对策.航海技术,94(3):8-9
[10]石博强,申炎华.机械故障诊断的分形方法——理论与时间.北京:冶金工业出版社.2000
[11]种秉林,黄仁.机械故障诊断学.北京:机械工业出版社.1999
[12]虞和济,侯广琳.故障诊断的专家系统.北京:冶金工业出版社.2000
[13]余华明.冷库及冷藏技术.北京:人民邮电出版社.1999
[14]辛长平.制冷设备运行管理与维修.北京:电子工业出版社.2002
[15]张新德.制冷电器维修培训强化教程.北京:人民邮电出版社.2001
[16]冯玉棋,刘旭.制冷装置维修速查图表.北京:人民邮电出版社.2002
[17]郑兆态.制冷装置电气控制系统原理与检修.北京:人民邮电出版社.2002
[18]康宁.常用空调冷冻设备技术.广州:华南理工大学出版社.2002
[19]Althouse,A.D.Modern Refrigeration＆Air-conditioning(彦启森译).上海:上海交通大学出版社.2002
[20]扬茅甄.中国港口协会.国际集装箱港口管理实务.上海:上海人民出版社.2005
[21]江静.国际集装箱运输与多式联运.北京:中国商务出版社.2005
[22]韦在军、夏汉青、郭伟.基于GPRS通信技术的船载远程视频监控系统.数据通信,2004(1):23-26
[23]廖海风.船舶冷藏集装箱故障研究与故障数据库开发:[学位论文].上海海事大学,2004
[24]肖新文.船舶冷藏集装箱制冷系统故障遥测及诊断研究:[学位论文].上海海事大学,2002
[25]张珍.冷藏集装箱远程故障诊断系统研究:[学位论文].上海海事大学,2005
[26]梅雪莲.冷藏集装箱环境室测控系统研究:[学位论文].上海海事大学,2004
[27]彭强.复杂系统远程智能故障诊断技术研究:[学位论文].南京理工大学,2004
[28]王凤岭.ACCESS2002实用教程.北京:电子工业出版社.2003
[29]ACCESS2003数据库管理.北京:人民邮电出版社.2006
[30]江志文.新编Visual Basic程序设计教程第1版.广州:中山大学出版社.2005
[31]李晓黎,张巍.Visual Basic+SQL Server数据库应用系统开发与实例.第1版。北京:人民邮电出版社.2003
[32]曾声奎,赵廷弟,张建国等.系统可靠性设计分析教程.北京:北京航空航天大学出版社.2001
[33]刘鼎铭.冷冻集装箱.北京:人民交通出版社.1985
[34]卢士勋.制冷与空气调节技术.上海:上海科学普及出版社.1992
[35]陈芝久.制冷系统热动力学.北京:机械工业出版社.1998
[36]YORK MARINE.Instruction Manual Operating Guide-REFCON Reefer Container Monitoring System.2006
[37]扬晓楼,许茂增.我国冷藏食品物流市场现状及发展措施.重庆交通学院院报,2005(6):24-26
[38]谢如鹤,韩伯领.国内外冷藏食品物流的现状.中国储运,2004(6):16-18